Differential Carrier

Differential Carrier

















Removal

1. Remove the axle assembly. For additional information, refer to Axle Assembly Axle Assembly.

2. Remove the 10 differential housing cover bolts and the differential housing cover.

3. Remove the 2 differential bearing caps.

1. Remove the 4 differential bearing cap bolts.

2. Remove and identify the 2 differential bearing caps.





4. Install the Adapters.





5. Install the axle assembly and Transmission Holding Fixture into the bench fixture.





6. Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier Spreader.





7. NOTICE: Overspreading can damage the differential housing.

Spread the differential housing to the specification.

1. Adjust the Dial Indicator Gauge to zero.

2. Tighten the Differential Carrier Spreader screw.

3. Remove the Dial Indicator Gauge.





8. NOTICE: Use wood blocks to avoid damaging the differential housing.

Remove the differential assembly from the housing.

1. Position the wood blocks.

2. Push downward on the pry bars.

3. Remove the differential assembly.

4. Remove the Differential Carrier Spreader.





Installation

1. Install the Differential Carrier Spreader, Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
- Position the Clutch Housing Gauge needle in the Differential Carrier Spreader adapter hole.





2. NOTICE: Overspreading can damage the differential housing.

Spread the differential housing to the specification.





3. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.





4. NOTE: Push the differential assembly downward to fully seat the differential bearing cups in the differential housing.

Install the differential bearing cups and the differential assembly in the differential housing.

1. Position the 2 differential bearing cups on the 2 differential bearings.

2. Lower the differential assembly in place.





5. NOTICE: Do not tighten the 4 differential bearing cap bolts to specification at this time.

Install the 2 differential bearing caps in their original positions.

1. Position the 2 differential bearing caps.

2. Install the 4 differential bearing cap bolts hand-tight.





6. Remove the Differential Carrier Spreader.

7. Tighten the 4 differential bearing cap bolts.
- Tighten to 61 Nm (45 lb-ft).





8. Verify that the differential assembly rotates freely.

9. Check the ring gear backlash and remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.





10. Install the RH axle shaft.

11. NOTE: The machined surfaces on the differential housing and the differential housing cover must be clean and free of oil before applying the new silicone sealant. Cover the inside of the axle before cleaning the machined surface to prevent contamination.

NOTE: Install the differential housing cover within 15 minutes of applying the silicone material.

NOTE: Allow the sealant to cure for one hour before filling the axle with lubricant.

Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover mounting surface as shown.





12. Install the differential housing cover and the 10 differential housing cover bolts.
- Tighten to 29 Nm (21 lb-ft).

13. Install the axle assembly. For additional information, refer to Axle Assembly Axle Assembly.

14. Remove the fill plug and fill the axle with rear axle lubricant to 9.56 mm (0.38 in) below the bottom of the filler hole.

15. Install the fill plug.
- Tighten to 27 Nm (20 lb-ft).